Small scale,grain size and substrate effects in nano-indentation experiment of film–substrate systems

The mechanical properties of film–substrate systems have been investigated through nano-indentation experiments in our former paper (Chen, S.H., Liu, L., Wang, T.C., 2005. Investigation of the mechanical properties of thin films by nano-indentation, considering the effects of thickness and different coating–substrate combinations. Surf. Coat. Technol., 191, 25–32), in which Al–Glass with three different film thicknesses are adopted and it is found that the relation between the hardness H and normalized indentation depth h/t, where t denotes the film thickness, exhibits three different regimes: (i) the hardness decreases obviously with increasing indentation depth; (ii) then, the hardness keeps an almost constant value in the range of 0.1–0.7 of the normalized indentation depth h/t; (iii) after that, the hardness increases with increasing indentation depth. In this paper, the indentation image is further investigated and finite element method is used to analyze the nano-indentation phenomena with both classical plasticity and strain gradient plasticity theories. Not only the case with an ideal sharp indenter tip but also that with a round one is considered in both theories. Finally, we find that the classical plasticity theory can not predict the experimental results, even considering the indenter tip curvature. However, the strain gradient plasticity theory can describe the experimental data very well not only at a shallow indentation depth but also at a deep depth. Strain gradient and substrate effects are proved to coexist in film–substrate nano-indentation experiments.     

Size-dependent sharp indentation-II: a reverse algorithm to identify plastic properties of metallic materials

In part I of this paper (Cao and Lu, J. Mech. Phys. Solids, in press), a closed-form expression of the size-dependent sharp indentation loading curve has been proposed. In this second part, which concerns the direct application of the analytical model, a reverse algorithm has first been established to extract the plastic properties of metallic materials on a small scale where the size effect caused by geometrically necessary dislocations is significant. Second, from the viewpoint of the mathematical theory of inverse problems, the properties of the present inverse problem i.e. the existence, uniqueness and stability of the solution, have been investigated systematically. The results have identified the extent to which the plastic properties of ductile materials can be determined effectively using the present method. Third, experimental verifications of the reverse algorithm using a standard Berkovich indenter have been carried out for 316 stainless steel and pure titanium, respectively. The results show that, by taking a maximum indentation depth of 1.5 and , respectively for the two materials, a good engineering estimation of the representative stresses, σ_0.033, in the absence of a strain gradient can be made using the present method, which can be used in conjunction with the representative stress corresponding to another indenter with a different tip apex angle to determine the plastic properties of metallic materials, i.e. the yield strength σ_y and the strain hardening exponent n. The material length scale can also be identified by using the present algorithm. Experimental results show that it has the correct order of magnitude, but is more sensitive to data errors than the identified representative stress.     

Size effects in the conical indentation of an elasto-plastic solid

The size effect in conical indentation of an elasto-plastic solid is predicted via the Fleck and Willis formulation of strain gradient plasticity (Fleck, N.A. and Willis, J.R., 2009, A mathematical basis for strain gradient plasticity theory. Part II: tensorial plastic multiplier, J. Mech. Phys. Solids, 57, 1045–1057). The rate-dependent formulation is implemented numerically and the full-field indentation problem is analyzed via finite element calculations, for both ideally plastic behavior and dissipative hardening. The isotropic strain-gradient theory involves three material length scales, and the relative significance of these length scales upon the degree of size effect is assessed. Indentation maps are generated to summarize the sensitivity of indentation hardness to indent size, indenter geometry and material properties (such as yield strain and strain hardening index). The finite element model is also used to evaluate the pertinence of the Johnson cavity expansion model and of the Nix–Gao model, which have been extensively used to predict size effects in indentation hardness.     

考虑压头曲率半径和应变梯度的微压痕分析

在压头尖端曲率半径取100nm的前提下，采用Chen和Wang的应变梯度理论，对微压痕实验进行了系统的数值分析. 首先通过拟合载荷-位移实验曲线的后半段来确定材料的屈服应力和幂硬化指数值,然后用有限元方法数值模拟压痕实验，并将计算得到的整段载荷-位移曲线及硬度-位移曲线和实验结果进行了比较. 结果表明应变梯度理论所预测的计算结果和实验结果很好地符合,包括压痕深度在亚微米和微米范围内的整段曲线.     

A numerical approach to spherical indentation techniques for material property evaluation

In this work, some inaccuracies and limitations of prior indentation theories, which are based on experimental observations and the deformation theory of plasticity, are investigated. Effects of major material properties on the indentation load-deflection curve are examined via finite element (FE) analyses based on incremental plasticity theory. It is confirmed that subindenter deformation and stress-strain distribution from deformation plasticity theory are quite dissimilar to those obtained from incremental plasticity theory. We suggest an optimal data acquisition location, where the strain gradient is the least and the effect of friction is negligible. A new numerical approach to indentation techniques is then proposed by examining the FE solutions at the optimal point. Numerical regressions of obtained data exhibit that the strain-hardening exponent and yield strain are the two key parameters which govern the subindenter deformation characteristics. The new indentation theory successfully provides a stress-strain curve and material properties with an average error of less than 3%.     

Mechanism-based strain gradient crystal plasticity—II. Analysis

In part I of this series (Mechanism-based strain gradient crystal plasticity—I. Theory. J. Mech. Phys. Sol. (2005), accepted for publication), we have proposed a theory of mechanism-based strain gradient crystal plasticity (MSG-CP) to model the effect of inherent anisotropy of a crystal lattice on size-dependent non-uniform plastic deformation at micron and submicron length scales. In the present paper, several example problems are investigated to show how crystal anisotropy is reflected by the MSG-CP theory.     

Mechanics of indentation of plastically graded materials—I: Analysis

The introduction of controlled gradients in plastic properties is known to influence the resistance to damage and cracking at contact surfaces in many tribological applications. In order to assess potentially beneficial effects of plastic property gradients in tribological applications, it is essential first to develop a comprehensive and quantitative understanding of the effects of yield strength and strain hardening exponent on contact deformation under the most fundamental contact condition: normal indentation. To date, however, systematic and quantitative studies of plasticity gradient effects on indentation response have not been completed. A comprehensive parametric study of the mechanics of normal indentation of plastically graded materials was therefore undertaken in this work by recourse to finite element method (FEM) computations. On the basis of a large number of computational simulations, a general methodology for assessing instrumented indentation response of plastically graded materials is formulated so that quantitative interpretations of depth-sensing indentation experiments could be performed. The specific case of linear variation in yield strength with depth below the indented surface is explored in detail. Universal dimensionless functions are extracted from FEM simulations so as to predict the indentation load versus depth of penetration curves for a wide variety of plastically graded engineering metals and alloys for interpretation of, and comparisons with, experimental results. Furthermore, the effect of plasticity gradient on the residual indentation pile-up profile is systematically studied. The computations reveal that pile-up of the graded alloy around the indenter, for indentation with increasing yield strength beneath the surface, is noticeably higher than that for the two homogeneous reference materials that constitute the bounding conditions for the graded material. Pile-up is also found to be an increasing function of yield strength gradient and a decreasing function of frictional coefficient. The stress and plastic strain distributions under the indenter tip with and without plasticity gradient are also examined to rationalize the predicted trends. In Part II of this paper, we compare the predictions of depth-sensing indentation and pile-up response with experiments on a specially made, graded model Ni-W alloy with controlled gradients in nanocrystalline grain size.     

Mechanism-based strain gradient plasticity in C0 axisymmetric element

Non-uniform plastic deformation of materials exhibits a strong size dependence when the material and deformation length scales are of the same order at micro- and nano-metre levels. Recent progresses in testing equipment and computational facilities enhancing further the study on material characterization at these levels confirmed the size effect phenomenon. It has been shown that at this length scale, the material constitutive condition involves not only the state of strain but also the strain gradient plasticity. In this study, C⁰ axisymmetric element incorporating the mechanism-based strain gradient plasticity is developed. Classical continuum plasticity approach taking into consideration Taylor dislocation model is adopted. As the length scale and strain gradient affect only the constitutive relation, it is unnecessary to introduce either additional model variables or higher order stress components. This results in the ease and convenience in the implementation. Additional computational efforts and resources required of the proposed approach as compared with conventional finite element analyses are minimal. Numerical results on indentation tests at micron and submicron levels confirm the necessity of including the mechanism-based strain gradient plasticity with appropriate inherent material length scale. It is also interesting to note that the material is hardened under Berkovich compared to conical indenters when plastic strain gradient is considered but softened otherwise.     

Crack separation energy-rates for the DBCS model under biaxial modes of loading

A Modified version of the Dugdale-Bilby-Cottrell-Swinden (DBCS) model simulating the effect of plasticity at the tip of a crack in an infinite region was used by kfouri and rice (1978) to calculate the crack separation energy-rate G^Δ corresponding to a finite crack growth step Δa during plane strain mode I crack extension. The loading consisted of a remote uniaxial tension σp applied normally to the plane of the crack. Using Rice's path-independent integral J to characterize the applied load in the crack tip region, and assuming the length R of the crack tip plastic zone to be small compared with the length of the crack, an analytical expression was derived relating the ratios (J/G^Δ) and (2a/R) for small values of (2a/R). The analytical solution was incomplete in itself in that the value assumed in the plastic region of the DBCS model for the normal stress Y acting on the extending crack surfaces was the product of the yield stress in uniaxial tension σ_Y and an unknown parameter C, the value of which depends on the effect of the local hydrostatic stresses in the case of plane strain conditions. The analytical solution was compared with a numerical solution obtained from a plane strain elastic-plastic finite element analysis on a centre-cracked plate (CCP) of material obeying the von Mises yield criterion. The value used for the yield stress was 310 MN/m² and moderate isotropic linear hardening was applied with a tangent modulus of 4830 MN/m². A uniaxial tension σp was applied on the two appropriate sides of the plate. The comparisons showed that the analytical and finite element solutions were mutually consistent and they enabled the value of C to be established at 1.91. In the present paper similar comparisons are made between the analytical solution and the finite element solutions for the CCP of the same material under different biaxial modes of loading. By assuming further that the form of the analytical solution does not depend on the details of the geometry and of the loading at remote boundaries, a comparison has also been made with the results of a finite element analysis on a compact tension specimen (CTS) made of the same material as the CCP. The different values of C obtained in each case are consistent with investigations by other authors on the effect of load biaxiality on crack tip plasticity.     

Determination of the mechanical constants of ZnS nanobelt by combining nanoindentation test and finite element method

The single nanobelt simplified as transversely isotropic is modeled by three dimension element during the modeling of finite element method (FEM), and the mechanical constants of ZnS nanobelt are obtained by combining nanoindentation test and FEM. In the forward analysis, the numerical loading curves at the appropriate penetration depth are simulated by using the purely mechanical indentation (PMI) and piezoelectric indentation (PI) modes to extract the numerical maximum indentation load and numerical loading curve exponent, and they are used to establish the dimensionless equations related with the mechanical constants of nanobelt by fitting the mechanical constants vs numerical maximum indentation load and numerical loading curve exponent curves. In the reverse analysis, the experimental indentation curve performed on ZnS nanobelt is fitted as the power function to obtain the maximum indentation load and the loading curve exponent and they are substituted into the dimensionless equations to solve the mechanical constants of the nanobelt. In order to verify the validity, the mechanical constants are inputted into ABAQUS software to obtain the computational loading curves under PMI and PI modes, and they are in good agreement with the experimental indentation curve of ZnS nanobelt. The combination solutions of mechanical constants under PMI mode is of larger total error than those under PI mode, and it indicates that the piezoelectric effect should be reasonably considered into the developed method, which is effective to determine the mechanical property of single nanobelt.     

Strain gradient plasticity modeling of the cyclic behavior of laminate microstructures

Two recently proposed Helmholtz free energy potentials including the full dislocation density tensor as an argument within the framework of strain gradient plasticity are used to predict the cyclic elastoplastic response of periodic laminate microstructures. First, a rank-one defect energy is considered, allowing for a size-effect on the overall yield strength of micro-heterogeneous materials. As a second candidate, a logarithmic defect energy is investigated, which is motivated by the work of Groma et al. (2003). The properties of the back-stress arising from both energies are investigated in the case of a laminate microstructure for which analytical as well as numerical solutions are derived. In this context, a new regularization technique for the numerical treatment of the rank-one potential is presented based on an incremental potential involving Lagrange multipliers. The results illustrate the effect of the two energies on the macroscopic size-dependent stress–strain response in monotonic and cyclic shear loading, as well as the arising pile-up distributions. Under cyclic loading, stress–strain hysteresis loops with inflections are predicted by both models. The logarithmic potential is shown to provide a continuum formulation of Asaro's type III kinematic hardening model. Experimental evidence in the literature of such loops with inflections in two-phased FFC alloys is provided, showing that the proposed strain gradient models reflect the occurrence of reversible plasticity phenomena under reverse loading.     

A finite deformation theory of strain gradient plasticity

Plastic deformation exhibits strong size dependence at the micron scale, as observed in micro-torsion, bending, and indentation experiments. Classical plasticity theories, which possess no internal material lengths, cannot explain this size dependence. Based on dislocation mechanics, strain gradient plasticity theories have been developed for micron-scale applications. These theories, however, have been limited to infinitesimal deformation, even though the micro-scale experiments involve rather large strains and rotations. In this paper, we propose a finite deformation theory of strain gradient plasticity. The kinematics relations (including strain gradients), equilibrium equations, and constitutive laws are expressed in the reference configuration. The finite deformation strain gradient theory is used to model micro-indentation with results agreeing very well with the experimental data. We show that the finite deformation effect is not very significant for modeling micro-indentation experiments.     

The finite deformation theory of Taylor-based nonlocal plasticity

Recent experiments have shown that metallic materials display significant size effect at the micron and sub-micron scales. This has motivated the development of strain gradient plasticity theories, which usually involve extra boundary conditions and possibly higher-order governing equations. We propose a finite deformation theory of nonlocal plasticity based on the Taylor dislocation model. The theory falls into Rice's theoretical framework of internal variables [J Mech Phys Solids 19 (1971) 433], and it does not require any extra boundary conditions. We apply the theory to study the micro-indentation hardness experiments, and it agrees very well with the experimental data over a wide range of indentation depth.     

Finite element solutions for plane strain mode I crack with strain gradient effects

In this paper, a new phenomenological theory with strain gradient effects is proposed to account for the size dependence of plastic deformation at micro- and submicro-length scales. The theory fits within the framework of general couple stress theory and three rotational degrees of freedom ω_i are introduced in addition to the conventional three translational degrees of freedom u_i. ω_i is called micro-rotation and is the sum of material rotation plus the particles' relative rotation. While the new theory is used to analyze the crack tip field or the indentation problems, the stretch gradient is considered through a new hardening law. The key features of the theory are that the rotation gradient influences the material character through the interaction between the Cauchy stresses and the couple stresses; the term of stretch gradient is represented as an internal variable to increase the tangent modulus. In fact the present new strain gradient theory is the combination of the strain gradient theory proposed by Chen and Wang (Int. J. Plast., in press) and the hardening law given by Chen and Wang (Acta Mater. 48 (2000a) 3997). In this paper we focus on the finite element method to investigate material fracture for an elastic-power law hardening solid. With remotely imposed classical K fields, the full field solutions are obtained numerically. It is found that the size of the strain gradient dominance zone is characterized by the intrinsic material length l₁. Outside the strain gradient dominance zone, the computed stress field tends to be a classical plasticity field and then K field. The singularity of stresses ahead of the crack tip is higher than that of the classical field and tends to the square root singularity, which has important consequences for crack growth in materials by decohesion at the atomic scale.     

RVE-based studies on the coupled effects of void size and void shape on yield behavior and void growth at micron scales

The present paper extends the Gurson and GLD models [Gurson, A.L., 1977. Continuum theory of ductile rupture by void nucleation and growth, Part I—yield criteria and flow rules for porous ductile media. J. Mech. Phys. Solids 99, 2–15; Gologanu, M., Leblond, J.B., Devaux, J., 1993. Approximate models for ductile metals containing non-spherical voids—case of axisymmetric prolate ellipsoidal cavities. J. Mech. Phys. Solids 41, 1723–1754; Gologanu, M., Leblond, J.B., Devaux, J., 1994. Approximate models for ductile metals containing non-spherical voids—case of axisymmetric oblate ellipsoidal cavities. J. Eng. Mater. Technol. 116, 290–297] to involve the coupled effects of void size and void shape on the macroscopic yield behavior of non-linear porous materials and on the void growth. A spheroidal representative volume element (RVE) under a remote axisymmetric homogenous strain boundary condition is carefully analyzed. A wide range of void aspect ratios covering the oblate spheroidal, spherical and prolate spheroidal void are taken into account to reflect the shape effect. The size effect is captured by the Fleck–Hutchinson phenomenological strain gradient plasticity theory [Fleck, N.A., Hutchinson, J.W., 1997. Strain gradient plasticity. In: Hutchinson, J.W., Wu, T.Y. (Eds.), Advance in Applied Mechanics, vol. 33, Academic Press, New York, pp. 295–361]. A new size-dependent damage model like the Gurson and GLD models is developed based on the traditional minimum plasticity potential principle. Consequently, the coupled effects of void size and void shape on yield behavior of porous materials and void growth are discussed in detail. The results indicate that the void shape effect on the yield behavior of porous materials and on the void growth can be modified dramatically by the void size effect and vice versa. The applied stress triaxiality plays an important role in these coupled effects. Moreover, there exists a cut-off void radius r_c, which depends only on the intrinsic length l₁ associated with the stretch strain gradient. Voids of effective radius smaller than the critical radius r_c are less susceptible to grow. These findings are helpful to our further understanding to some impenetrable micrographs of the ductile fracture surfaces.     

Indentation of a hard film on a soft substrate: Strain gradient hardening effects

The strain gradient work hardening is important in micro-indentation of bulk metals and thin metallic films, though the indentation of thin films may display very different behavior from that of bulk metals. We use the conventional theory of mechanism-based strain gradient plasticity (CMSG) to study the indentation of a hard tungsten film on soft aluminum substrate, and find good agreement with experiments. The effect of friction stress (intrinsic lattice resistance), which is important in body-center-cubic tungsten, is accounted for. We also extend CMSG to a finite deformation theory since the indentation depth in experiments can be as large as the film thickness. Contrary to indentation of bulk metals or soft metallic films on hard substrate, the micro-indentation hardness of a hard tungsten film on soft aluminum substrate decreases monotonically with the increasing depth of indentation, and it never approaches a constant (macroscopic hardness). It is also shown that the strain gradient effect in the soft aluminum substrate is insignificant, but that in the hard tungsten thin film is important in shallow indentation. The strain gradient effect in tungsten, however, disappears rapidly as the indentation depth increases because the intrinsic material length in tungsten is rather small.     

A model of size effects in nano-indentation

The indentation hardness-depth relation established by Nix and Gao [1998. Indentation size effects in crystalline materials: a law for strain gradient plasticity. J. Mech. Phys. Solids 46, 411-425] agrees well with the micro-indentation but not nano-indentation hardness data. We establish an analytic model for nano-indentation hardness based on the maximum allowable density of geometrically necessary dislocations. The model gives a simple relation between indentation hardness and depth, which degenerates to Nix and Gao [1998. Indentation size effects in crystalline materials: a law for strain gradient plasticity. J. Mech. Phys. Solids 46, 411-425] for micro-indentation. The model agrees well with both micro- and nano-indentation hardness data of MgO and iridium.     

Mode I and mixed mode crack-tip fields in strain gradient plasticity

Strain gradients develop near the crack-tip of Mode I or mixed mode cracks. A finite strain version of the phenomenological strain gradient plasticity theory of Fleck-Hutchinson (2001) is used here to quantify the effect of the material length scales on the crack-tip stress field for a sharp stationary crack under Mode I and mixed mode loading. It is found that for material length scales much smaller than the scale of the deformation gradients, the predictions converge to conventional elastic-plastic solutions. For length scales sufficiently large, the predictions converge to elastic solutions. Thus, the range of length scales over which a strain gradient plasticity model is necessary is identified. The role of each of the three material length scales, incorporated in the multiple length scale theory, in altering the near-tip stress field is systematically studied in order to quantify their effect.     

Analyses of steady quasistatic crack growth in plane strain tension in elastic-plastic materials with non-isotropic hardening

Steady state crack propagation problems of elastic-plastic materials in Mode I, plane strain under small scale yielding conditions were investigated with the aid of the finite element method. The elastic-perfectly plastic solution shows that elastic unloading wedges subtended by the crack tip in the plastic wake region do exist and that the stress state around the crack tip is similar to the modified Prandtl fan solution. To demonstrate the effects of a vertex on the yield surface, the small strain version of a phenomenological J₂, corner theory of plasticity (Christoffersen, J. and Hutchinson, J. W. J. Mech. Phys. Solids,27, 465 C 1979) with a power law stress strain relation was used to govern the strain hardening of the material. The results are compared with the conventional J₂ incremental plasticity solution. To take account of Bauschinger like effects caused by the stress history near the crack tip, a simple kinematic hardening rule with a bilinear stress strain relation was also studied. The results are again compared with the smooth yield surface isotropic hardening solution for the same stress strain curve. There appears to be more potential for steady state crack growth in the conventional J₂ incremental plasticity material than in the other two plasticity laws considered here if a crack opening displacement fracture criterion is used. However, a fracture criterion dependent on both stress and strain could lead to a contrary prediction.     

Scale-dependent plasticity potential of porous materials and void growth

In the present paper, a boundary value problem about the macroscopic response and its microscopic mechanism of a representative spherical cell with a spherical microvoid under axisymmetric triaxial tension has been theoretically investigated. To capture the size effects of local plastic deformation in the matrix, the strain gradient constitutive theory including the rotation and the stretch gradients developed by Fleck and Hutchinson [Strain gradient plasticity, in: J.W. Hutchinson, T.Y. Wu (Eds.), Advance in Applied Mechanics, vol. 33, Academic Press, New York, 1997, p. 295] is adopted. By means of the principle of minimum plasticity potential and the Lagrange multipliers method, the self-contained displacement field within the matrix has been computationally determined. Based on these, a size-dependent constitutive potential theory for porous material has been developed. The results indicate clearly that the microvoid evolution predicted by the present constitutive model displays very significant dependences on the void size especially when the radius a of microvoids is comparable with the intrinsic characteristic length l of the matrix. And when the void radius a is much lager than l, the present model can retrogress automatically to the Gurson model improved by Wang and Qin [Acta Mech. Solid. Sin. 10 (1989) 127, in Chinese].